Acoustic partition for removable panel finishing system

ABSTRACT

An acoustical absorbing membrane that may be used in removable panel finishing systems is provided. The acoustic membrane may be formed of any sound transmission loss material that possesses sound-absorbing or sound-deadening qualities. Examples of suitable materials include foil, a foil-faced asphalt material, elastomeric materials, composite laminates, a polymer film, a composite material formed of an organic bonding material and one or more types of reinforcement fibers, a cement board, a gypsum board, a gypsum/WUCS board, a dense WUCS mat, a film formed of a fiberglass reinforced resin, and/or any dense polymeric material. In at least one exemplary embodiment, the acoustic membrane may be a film formed of a loaded polymer or copolymer, such as a copolymer of ethylene-vinyl acetate loaded with barium or CaCO 3 . The acoustic membrane may have a density of approximately 1 lb/ft 2 -3 lbs/ft 2  and preferably has a thickness from about 1/16-⅜ of an inch.

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION

The present invention relates generally to removable panel finishingsystems, and more particularly, to an acoustic partition that increasessound absorption in a removable panel finishing system for rooms such asmay be found in single family homes or commercial buildings.

BACKGROUND OF THE INVENTION

Sound insulation materials are used in a variety of settings where it isdesired to dampen noise from an external source. For example, soundinsulation materials have been used in applications such as inappliances to reduce the sound emitted into the surrounding areas of ahome, in automobiles to reduce mechanical sounds of the motor and roadnoise, and in office buildings to attenuate sound generated from theworkplace, such as from telephone conversations or from the operation ofoffice equipment. Acoustical insulation materials typically relies uponboth sound absorption (i.e., the ability to absorb incident sound waves)and transmission loss (i.e., the ability to reflect incident soundwaves) to provide adequate sound attenuation.

Conventional acoustical insulation materials include materials such asfoams, compressed fibers, fiberglass batts, felts, and nonwoven webs offibers such as meltblown fibers. Laminates formed of one or more layersof insulation provide the desired acoustical and insulating propertiesand one or more additional layers of a rigid material provide desiredmechanical strength properties and permit simple and convenientinstallation as well as proper functional performance. Such insulationmaterials may be used in the walls of single family homes and commercialbuildings to both insulate and reduce sound emission from the rooms.Some examples of conventional acoustical materials are set forth below.

U.S. Patent Publication No. 2004/0077247 to Schmidt et al. describes anonwoven laminate that contains a first layer formed of thermoplasticspunbond filaments having an average denier less than about 1.8 dpf anda second layer containing thermoplastic multicomponent spunbondfilaments having an average denier greater than about 2.3 dpf. Thelaminate has a structure such that the density of the first layer isgreater than the density of the second layer and the thickness of thesecond layer is greater than the thickness of the first layer.

U.S. Patent Publication No. 2004/0002274 A1 to Tilton discloses alaminate material that includes (1) a base layer formed of polyester,polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon,and blends thereof and (2) a facing layer. The base layer has a densityof from approximately 0.5-15.0 pcf and the facing layer has a density ofbetween about 10 pcf and about 100 pcf.

U.S. Pat. No. 6,758,305 to Gelin et al. discloses a sound-deadeninglaminate that is formed of a structural skin and a layer of asound-deadening material. The sound deadening material has an equivalentYoung's Modulus between 50 and 600 psi. It is taught that the laminatemay be attached to the framing members of a building.

U.S. Pat. No. 6,152,259 to Freist et al. teaches a sound-deadeninglaminate that has a bituminous layer more than 1 mm thick bonded to oneside of a thermal insulation layer such as foam or felt. An adhesivelayer (e.g., cement) is positioned on the opposing side of the thermalinsulation layer so that the laminate can be affixed to a component tobe acoustically improved.

U.S. Pat. No. 5,886,306 to Patel et al. discloses a layered acousticalinsulating web that includes a series of cellulose fiber layerssandwiched between a layer of melt-blown or spun-bond thermoplasticfibers (e.g., polypropylene) and a layer of film, foil, paper, orspunbond thermoplastic fibers.

U.S. Pat. No. 5,185,197 to Nixon discloses an acoustic panel that isformed of a lightweight fiberglass core with a white or light coloredglass mat positioned on a first surface. The glass mat may be attachedto the fiberglass core by an adhesive. A textured paint is applied tothe outwardly facing surface of the glass mat to provide anaesthetically pleasing surface. It is preferred that a thin textures ofcolored, tiny flakes are applied to produce a mottling appearance.

U.S. Pat. No. 4,948,660 to Rias et al. describes a heat and soundinsulating panel that is formed of an outer layer of glass fibers, aninsulating layer of glass fibers bound by an organic binder, and analuminum film positioned between the outer layer and the insulatinglayer. The aluminum film has a thickness less than or equal to 9microns.

In newly constructed homes, it has become more commonplace to leaverooms unfinished and for the homeowners to finish the rooms themselvesas more money becomes available or as the homeowner's family grows.Removable panel systems, such as the finishing system disclosed anddescribed in U.S. Patent Publication No. 2004/0219853 to Weir, et al.entitled Room Finishing System, herein incorporated by reference in itsentirety, provide an insulation system for a room that is easy toinstall and maintain. The finishing system described in Weir et al.contains a plurality of frame members attached to a masonry wall, aplurality of insulation panels, and first and second snap-in connectorsto hold the insulation panels within the frame members. The second snapin connectors are releasably connected to one of the first connectors topermit easy removal of the insulation panel.

Other examples of wall finishing systems are described below.

U.S. Pat. No. 3,721,050 to Perina discloses a modular grid panelretention system that includes a framework attached to a masonry wall.Panels are attached to the framework by complementary hook and loopfasteners. The panels may be translucent to allow indirect lighting of abasement from behind the panels. It is taught that the grid panelretention system may be used in structures such as basements ofindustrial buildings and business establishments.

U.S. Pat. No. 5,606,833 to Andersson discloses a wall structure for theinterior sound and thermal insulation of rooms. The wall structureincludes one-piece metal fastening profiles attached to the walls of aroom or to composite insulating members to hold insulating membersagainst the walls. The insulating members each include a soft insulatingsheet fastened to a rigid support sheet. Fastening profiles fasten theinsulating members by inserting them between the soft and rigid sheetsand thus either attaching a particular insulating member directly to awall or to an adjoining insulating member.

U.S. Pat. No. 5,606,841 to Carter, Jr. discloses interior wall panelsthat have a rigid frame backing member to which an outer pliable sheetmaterial is secured. A filling or padding material is retained betweenthe sheet material and the backing member. The sheet material is securedthrough the filling at spaced locations to create a three dimensionalsurface relief. In some embodiments, the wall panels are constructed toprovide thermal and insulating properties.

Despite the numerous acoustical insulation products in existence in theart, none of the existing acoustical products provide sufficient soundattenuating properties for use in homes and commercial buildings. Thus,there remains a need in the art for insulation materials that haveimproved sound absorbing qualities, especially improved acousticalabsorbing materials that can be utilized in a removable panel finishingsystem.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an acousticalabsorbing membrane or acoustic partition that may be used in removablepanel finishing systems. The materials that form the acoustic membraneare not particularly limited so long as the materials possesssound-absorbing or sound-deadening qualities. Non-limiting examples ofsound transmission loss materials suitable for use as the soundabsorbing membrane include foil, a foil-faced asphalt material,elastomeric materials, composite laminates, a polymer film (e.g.,polyethylene, nylon, and the like), a composite material formed of anorganic bonding material and one or more types of reinforcement fibers,a cement board, a gypsum board, a gypsum/WUCS (wet use chopped strandglass) board, a dense WUCS mat, a film formed of a fiberglass reinforcedresin, or any other dense polymeric material. The acoustic membrane mayalso be a film formed of a loaded polymer or copolymer such as acopolymer of ethylene-vinyl acetate (EVA) loaded with barium or CaCO₃.In addition, the acoustic membrane may be rigid, flexible, orsemi-flexible. The acoustic membrane may have a density of approximately1 lb/ft²-3 lbs/ft² and preferably has a thickness from about 1/16 of aninch—about ⅜ of an inch.

It is also an object of the present invention to provide a removablepanel finishing system that includes an acoustic membrane describedherein to improve the sound absorbing properties of the finishingsystem. The acoustic membrane may be attached in a continuous orsuccessive fashion around the room to be finished and may be affixed tothe framing studs of the room by mechanical fasteners or adhesives.Joints between successive acoustic membranes may be sealed by tape orcaulk to form a substantially continuous acoustic membrane, andtherefore a continuous or nearly continuous sound barrier. A framemember formed of a base plate and two projecting arms may be attached toa stud through the acoustic membrane by mechanical fastening devicessuch that the arms of the frame member project away from the acousticmembrane and towards the interior of the room. Alternatively, the framemember may be affixed to the acoustic membrane by an adhesive.Insulating panels formed of an insulating core material, a fabric facer(such as a fabric or other decorative finish), and optionally a backingfacer are positioned between the base plate of the frame member andretaining arms of either a corner frame member (for positioning theinsulation panels in a corner of the room) or a divider member (forpositioning the insulation panels along a wall of the room). The cornerframe member and divider member are releasably connected to the framemember so that the insulation panels can be easily removed.

It is a further object of the present invention to provide a removablepanel finishing system that includes insulation panels having thereon anacoustic membrane described herein to improve the sound absorbingproperties of the finishing system. The insulation panels may be formedof an insulating core material, an acoustic membrane, and optionally abacking facer. In one exemplary embodiment, the acoustic membrane islaminated to the insulating core by the use of an adhesive afterformation of the insulating core material. Alternatively, the acousticmembrane may be adhered to the insulating core material either duringfabrication by introducing the acoustic membrane to the forming sectionof a glass wool process or prior to curing the glass wool. The acousticmembrane may be formed of a waterproof material so that the insulationpanels may be used in places where the insulation panel may be exposedto water or have a need to be cleaned, such as in a shower stall, near abathroom sink, in a kitchen, or in a recreational room. The insulatingpanels are positioned between the base plate of the frame member andretaining arms of either a corner frame member (for positioning theinsulation panels in a corner of the room) or a divider member (forpositioning the insulation panels along a wall of the room) with theacoustic membrane facing the internal portion of the room to befinished. The corner frame member and divider member are releasablyconnected to the frame member so that the insulation panels can beeasily removed.

It is yet another object of the present invention to provide a dropceiling utilizing a removable panel finishing system that includesinsulation panels having thereon an acoustic membrane described hereinto improve the sound absorbing qualities of the room. For example, adrop ceiling may be formed utilizing a removable panel system inconjunction with insulation panels formed of an insulating corematerial, an acoustic membrane, and optionally a backing facer. Aframing member is mechanically and/or adhesively fixed to a sub-floorframing member such that the arms of the framing member face downwardlyand into the interior of the room to be finished. The insulating panelsare positioned between the base plate of the frame member and retainingarms of a divider member with the acoustic membrane facing the internalportion of the room. The divider members are releasably connected to theframe member so that the insulation panels can be easily removed.

It is a further object of the present invention to provide a dropceiling utilizing a removable panel finishing system described herein.In this exemplary embodiment, an acoustic membrane such as describedabove may be mechanically affixed to sub-floor framing members in acontinuous or successive manner. Joints between successive acousticmembranes may be sealed, such as by tape or caulk, to form asubstantially continuous acoustic membrane across the ceiling (andtherefore form a continuous or nearly continuous sound barrier). Aframing member having a base plate and two arms extendingperpendicularly from the base plate may be mechanically and/oradhesively affixed to the sub-floor framing members such that the armsof the framing member face downwardly and into the interior of the roomto be finished. The insulation panels are positioned between the baseplate of the frame member and retaining arms of a divider member withthe fabric facing facing the internal portion of the room. As with theembodiments described above, the divider member is releasably connectedto the frame member so that the insulation panels can be easily removed.

It is an advantage of the present invention that unlike conventionaldrywall walls, there is little or no dust generated during installationof the removable panel finishing system.

It is another advantage of the present invention that the acousticmembrane can be easily cut, such as to fit around doors and/or windows.

It is yet another advantage of the present invention that a removablepanel finishing system utilizing the acoustic membrane absorbsapproximately 75% of the sound energy within the room.

It is a further advantage of the present invention that the acousticmembrane reduces echo time to less than about one second.

It is also an advantage of the present invention that the acousticmembrane can be fabricated to have an aesthetically pleasing surface.

The foregoing and other objects, features, and advantages of theinvention will appear more fully hereinafter from a consideration of thedetailed description that follows. It is to be expressly understood,however, that the drawings are for illustrative purposes and are not tobe construed as defining the limits of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages of this invention will be apparent upon consideration ofthe following detailed disclosure of the invention, especially whentaken in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of an acoustic membrane affixed to a frameaccording to at least one exemplary embodiment of the invention;

FIG. 2 is a cross sectional view of a frame member of a removable panelfinishing system affixed to a stud according to at least one exemplaryembodiment of the present invention;

FIG. 3 is a cross sectional view of a removable panel finishing systemin an inside corner of a room;

FIG. 4 is a cross sectional view of a removable panel finishing systemin an area of a room spaced from the corners of the room;

FIG. 5 is a cross-sectional view of an insulation panel according to atleast one exemplary embodiment of the present invention;

FIG. 6 is a partial view of a finished room having a removable panelfinishing system which utilizes an acoustic membrane according to atleast one exemplary embodiment of the present invention;

FIG. 7 is a is a cross-sectional view of an insulation panel accordingto at least one exemplary embodiment of the present invention in whichthe acoustic membrane is positioned on the outer surface of theinsulation panel;

FIG. 8 is a is a cross sectional view of a removable panel finishingsystem in an area of a room spaced from the corners of the room spacedfrom the corners of the room in which the acoustic membrane ispositioned on the outer surface of the insulation panel;

FIG. 9 is a partial perspective view of sub-floor framing members on amasonry wall; and

FIG. 10 is a cross sectional view of a drop ceiling formed by utilizinga removable panel finishing system.

DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention belongs. Although any methods andmaterials similar or equivalent to those described herein can be used inthe practice or testing of the present invention, the preferred methodsand materials are described herein. All references cited herein,including published or corresponding U.S. or foreign patentapplications, issued U.S. or foreign patents, or any other references,are each incorporated by reference in their entireties, including alldata, tables, figures, and text presented in the cited references.

In the drawings, the thickness of the lines, layers, and regions may beexaggerated for clarity. It is to be noted that like numbers foundthroughout the figures denote like elements. The terms “top”, “bottom”,“side”, “upper”, “lower” and the like are used herein for the purpose ofexplanation only. It will be understood that when an element is referredto as being “on,” another element, it can be directly on or against theother element or intervening elements may be present. If an element isdescribed as being “adjacent to” or “against” another element, it is tobe appreciated that the element may be directly adjacent or directlyagainst that other element, or intervening elements may be present. Itwill also be understood that when an element is referred to as being“over” another element, it can be directly over the other element, orintervening elements may be present.

The present invention relates, at least in part, to an acousticalabsorbing membrane or acoustic partition that may be used in removablepanel finishing systems. The components or materials that form theacoustic membrane are not particularly limited so long as thematerial(s) possess sound-absorbing or sound-deadening qualities.Non-limiting examples of sound transmission loss materials suitable foruse as the sound absorbing membrane include foil (e.g., aluminum foil),a foil-faced asphalt material, rubberized asphalt, asphalt, elastomericmaterials, composite laminates, a polymer film (e.g., polyethylene,polypropylene, polyethylene terephthalate (PET), ethylene vinyl acetate(EVA), and the like), or a composite material formed of an organicbonding material and one or more types of reinforcement fibers. Thereinforcing fibers may be any organic or inorganic fiber that possessesgood structural qualities as well as good acoustical and/or thermalproperties. In addition, the acoustic material may be a cement board, agypsum board, a gypsum/WUCS (wet use chopped strand glass) board, adense WUCS mat, a film formed of a fiberglass reinforced resin, or anyother dense polymeric material. For example, the acoustic membrane maybe a film formed of a loaded polymer or copolymer (e.g. a vinyl polymer)such as a copolymer of ethylene vinyl acetate (EVA) loaded with bariumor CaCO₃. Other non-limiting filler materials for the polymer orcopolymer include clay, iron, lead, steel, zinc, and stone. The acousticmembrane may be rigid, flexible, or semi-flexible. The acoustic membranemay have a density of from approximately 1 lb/ft²-3 lbs/ft², andpreferably has a density of from approximately 1 lb/ft²-2 lbs/ft². Inaddition, the acoustic membrane may have a thickness from about1/16—about ⅜ of an inch thick, preferably from abut ⅛—about ¼ of aninch.

In one exemplary embodiment of the invention, the acoustic membrane isaffixed to the frame of a room, such as in a residential home orcommercial building. As shown in FIG. 1, a frame 10 includes studs 12that interconnect a base member 14 and a top member 16. The studs may beformed of metal, wood, or any other suitable building framing material.Mechanical fasteners (e.g., nails, screws, tacks, staples, and the like)or adhesives may be used to fasten the acoustic membrane 20 to theframing studs 12. The acoustic membrane 20 may be attached in acontinuous or successive fashion around the room to be finished. Often,the acoustic membrane 20 is not of sufficient length to cover the frame10 of a room in one solid piece. Thus, joints between successiveacoustic membranes 20 (not shown) may be sealed, such as by tape orcaulk, to form a substantially continuous acoustic membrane 20. The term“substantially continuous acoustic membrane” as used herein is meant todenote a continuous acoustic membrane or a nearly continuous acousticmembrane.

After the attachment of the acoustic membrane 20 to the studs 12, aremovable panel finishing system may be placed on the acousticalmembrane to finish the room. As used herein, the terms “finish”,“finishing”, and “finished” refer to the process of installing aremovable panel finishing system to achieve a wall surface that would beacceptable for use in regularly inhabited rooms, including rooms in aresidential home or a commercial building. A drop ceiling or floortreatment such as tiling, carpeting, or hardwood flooring may beinstalled at the same time as the removable panel finishing system, butthese installations are not specifically required within the meaning ofthe terms “finish”, “finishing”, and “finished”.

As shown in FIG. 2, a frame member 22 may be attached to a stud 12through the acoustic membrane 20 by any conventional mechanicalfastening devices, such as, but not limited to, nails, screws, tacks, orstaples such that the arms 26 of the frame member 22 project away fromthe acoustic membrane 20. An adhesive may be used in addition tomechanical methods to attach the frame member 22 to a wall stud 12. Itis also considered within the purview of the invention to attach theframe member 22 to the acoustic membrane by an adhesive, provided thatthe acoustic membrane 20 is sufficiently strong to hold the frame member22 and the remaining portions of the panel finishing system describedhereafter.

A portion of an inside corner of a finished room is depicted in FIG. 3.In at least one exemplary embodiment of the invention, the corner of thefinished room includes a frame member 22 attached to the acousticmembrane 20 and a corner frame member 30 releasably connected to framemember 22. It is to be appreciated that, in FIG. 3, although the framemember 22 is shown as being affixed to the acoustic membrane 20 via anadhesive such as is described above, it could alternatively be affixedto a stud 12 located behind the base plate 24 of the frame member 22 bya mechanical fastening device and/or an adhesive (not shown). It shouldalso be understood that variations in the designs of frame members 22could occur and remain within the scope of the present invention.

As shown in FIG. 3, a releasable connection between the frame member 22and the corner frame member 30 may be achieved by catches 28 located onthe arms 26 of the frame member 22 (which form a female connector) and aconnection member 32 of the corner frame member 30 (which forms a maleconnector) and snaps between the catches 28 such that the catches 28releasably retain the connection member 32 therebetween. Alternatively,the releasable connection could be achieved by other arrangement ofelements. For example, the frame member 22 could bear a male connectorand the corner frame member 30 could bear a female connector. Othertypes of snap-in connectors or fast-release connectors known to those ofskill in the art may alternatively be used.

The corner frame member 30 includes a pair of retaining arms 34. Eachretaining arm 34 extends outwardly such that when the panel finishingsystem is assembled, at least a portion of each respective insulationpanel 40 is located between one of the retaining arms 34 and base plate24. The insulation panel 40 may have a fabric facing or decorativesurface 44 on the side facing the room to provide an aestheticallypleasing surface and a backing member 48 on the back surface of theinsulation panel 40 to provide additional support. The decorativesurface 44 may be colored and/or textured. The retaining arms 34 and thecorner frame member 30 thereby retain the insulation panels 40 againstthe base plate 24 and the acoustic membrane 20. It should be noted thatbecause the retaining arms 34 each extend across a portion of arespective insulation panel 40, there is a relatively large margin oferror available to an installer with respect the proper sizing of theinsulation panels 40 and the placement of the frame member 22 and thecorner frame member 30. In other words, there can be a relativelysizable gap between the end 42 of an insulation panel 40 and,respectively, the acoustic membrane 20 or arm 26 of the frame member 22,and the finished wall will still have an attractive appearance becausethe gap will be hidden behind a respective retaining arm 34. Thisfeature of the removable panel finishing system allows the installer tospend less time carefully measuring where to attach the frame member 22or where to cut an insulation panel 40 to fit it into an odd-sizedspace, with little appreciable reduction of overall thermal performance.

Turning now to FIG. 4, a portion of a finished room along a wall of aroom where two insulation panels 40 abut along the same wall can beseen. As illustrated in FIG. 4, two insulation panels 40 are retainedagainst the acoustical membrane 20 by the base plate 24 of the framemember 22 and a divider member 50 that are releasably connected. Thedivider member 50 includes two retaining arms 52 that maintain theinsulation panels 40 in positions adjacent the acoustic membrane 20 andmaintain an aesthetic appearance between the two insulation panels 40.It is to be appreciated that in FIGS. 3 and 4, many of the features ofthe releasable panel finishing system are the same regardless of theroom under consideration. Thus, it should be understood that thereleasable connection of the divider member 50 and corner frame member30, the operation and advantages of the retaining arms 52 and 34, andthe potential modifications of thereof as discussed herein, applyequally to both figures.

In at least one embodiment of the invention illustrated in FIG. 5, theinsulation panels 40 may be formed of an insulting core material 46, abacking facer 48 on the rear surface of the insulating core material 46,and a fabric facing 44 on the front surface of the insulating core 46.The backing facer 48 may be a glass mat facer and may have a weightbetween 10 and 40 lbs per ream (2880 Ft²). As shown in FIG. 5, thefabric facer 44 may be laminated to the insulating core 46 by the use ofan adhesive 49 after formation of the insulating core 46. Preferably,the adhesive has a flame retardancy of less than 25 flame spread and 450smoke generation (per ASTM-E85), applied at the rate of between 2gms/ft² and 8 gms/ft². Alternatively, the fabric facer 44 may be adheredto the insulating core material 46 either during fabrication byintroducing the fabric facer 44 to the forming section of a glass woolprocess or prior to curing the glass wool to form a board. The fabric onthe fabric facer 44 can be any type of decorative covering, includingnatural and artificial fiber fabrics. A durable fabric is preferred sothat when it is combined with the insulting core material 46, it willpass relevant UL flame and smoke spread tests. In addition, fabricfacing 44 provides aesthetics, abrasion resistance, cleanability,toughness, resiliency, rigidity, and elimination of occupant exposure tothe insulating core material 46 (e.g., a fiberglass core material).

The insulating core material 46 may be a foam or fibrous insulationboard or a combination of an insulation batt and an insulation board. Ifa foam insulation board is used, a preferred board would be constructedfrom a resilient melamine foam such as a melamine foam sold under theBasotect® by BASF. If a fibrous insulation board is used, a preferredboard is a 700 Series glass fiber insulation board available from OwensCorning, with a 703 Series board having a density of at least about 3lb/ft³ being particularly preferred. Such glass fiber insulation boardsare formed of glass fibers having a binder thereon which has been curedto bind the fibers into a matrix. For densities above about 2.25 lb/ft³,boards of such bindered glass fibers are relatively rigid and cangenerally support their own weight when stood on their end. Further,they do not sag by any significant amount when left in such a positionfor a long period of time. It is preferred that the insulating corematerial 46 and thus the insulation panels 40, whether they are foam orfibrous, be relatively rigid so that the panels 40 maintain their shapeover time. It is also preferred that the insulation panels 40 aretackable, e.g., that they are strong enough to hold the weight of apicture or other decorative hanging by means of one or more nails ortacks pushed into the insulation panels 40. It should be understood,however, that because such boards are preferably made from a resilientmelamine foam or a fibrous material, they have a generally soft,resilient surface and are relatively acoustically absorptive over amidrange of audible frequencies, e.g., a range including human speech,television programs, etc.

A finished room 60 with the removable panel finishing system describedabove is shown in FIG. 6. The finished room 60 includes a plurality ofdivider members 50 and corner frame members 30 (only one of which isshown in FIG. 6). The frame member 22 (not shown in FIG. 6), the dividermembers 50, the corner frame members 30, end trim members 64, and windowtrim members 66 are preferably composed of a polymer material (e.g.,polyethylene, polypropylene, polyvinyl chloride, or polystyrene) or ametal material. A polymer material is generally preferred over a metalmaterial to reduce the rate of heat conduction through the dividermembers 50, corner frame members 30, end trim members 64, and windowtrim members 66. The outer surfaces of the trim frame members 62 may betreated in a manner well-known in the art such that they possess adecorative finish, such as a simulated wood grain finish. The room 60may also include a floor 68 and a ceiling 70. The ceiling 70 is shown inthe FIG. 6 for convenience as a drywall ceiling, but it mayalternatively be some form of a drop ceiling. The floor 68 is depictedin FIG. 6 as a tile floor. However, the floor 68 may be carpeted, be awood floor, or be otherwise covered with a suitable flooring material.In addition, the room 60 may have windows and doors therein, such aswindow 72.

In an alternate embodiment of the invention, the acoustic membrane 20 ispre-applied to the core layer 46 of an insulation panel. Similar to thefabric facer 44 described above, the acoustic membrane 20 may belaminated to the insulating core 46 by the use of an adhesive 49 afterformation of the insulating core material 46. Alternatively, theacoustic membrane 20 may be adhered to the insulating core material 46either during fabrication by introducing the acoustic membrane 20 to theforming section of a glass wool process or prior to curing the glasswool. FIG. 7 depicts an insulation panel 74 in which the acousticmembrane 20 is affixed to the insulating core material 46 with anadhesive 49. A backing facer may optionally be applied to the backsurface of the insulating core material 46 of insulation panel 74(embodiment not illustrated). In FIG. 7, it is to be appreciated thatthe acoustic membrane 20 forms the external or exposed surface of theinsulation panel 74. The acoustic membrane 20 may be fabricated toresemble stucco, bathroom tiles, wood, etc. In addition, the acousticmembrane 20 may be formed of any of the materials set forth above. Forexample, the acoustic membrane may be formed of a waterproof materialsuch as a dense WUCS material, which would enable the insulation panel74 to be used in places where the panel 72 may be exposed to water orhave a need to be cleaned, such as in a shower stall, near a bathroomsink, in a kitchen, in a recreational room, etc.

Insulation panel 74 may be utilized in the removable panel finishingsystem described above in an manner very similar to insulation panel 40.For example, as shown in FIG. 8, a frame member 22 may be mechanicallyand/or adhesively fastened to a stud 12. Two insulation panels 74 areretained between the base plate 24 of a frame member 22 and the dividermember 50 by the retaining arms 52. As with the embodiment describedabove, divider member 50 is releasably connected to the frame member 22for ease of removing the insulation panels 74. The insulation panel 74is positioned between the divider member 50 and the base plate 24 in amanner such that the acoustic membrane 20 faces the inside of the room.It is also envisioned that the insulation panel 74 may further include afabric facer and that the insulation panel 74 may be positioned betweenthe divider member 50 and the base plate 24 such that the fabric facerfaces towards the inside of the room.

It is to be appreciated that in both the insulation panel 40 and theinsulation panel 74, the thickness of the acoustic membrane 20 and theinsulation panel are not particularly limited, so long as the totalthickness of the acoustic membrane 20 and the insulation panel do notexceed the length of the arms 26 of the frame member 22 to anyappreciable degree. The thickness is desirably a thickness in which theinsulation panel 40 or insulation panel 74 fits snugly between theretaining arms 34, 52 and the base plate 24 of the frame member 22. Ifthe thickness of the acoustic membrane 20 and the insulation panel 40 or74 is too small, a gap between the retaining arms 34, 52 and the baseplate 24 would form, which would cause the insulation panel 40 (or theinsulation panel 74) to move freely between the retaining arms 34, 52and the base plate 24 of the frame member 22.

In another exemplary embodiment of the present invention, the insulationpanel 74 may be used to form a drop ceiling, such as in a basement orother room. An unfinished basement is typically formed of a masonry wall80 (e.g., cinder blocks) and sub-floor framing members 82 as showngenerally in FIG. 9. A drop ceiling may be formed utilizing theremovable panel system described above in conjunction with insulationpanel 74. An example of the positioning of a framing member andinsulation panels 74 is depicted in FIG. 10. A framing member 22 ismechanically and/or adhesively fixed to a sub-floor framing member suchthat the arms 26 of the framing member 22 face downwardly and into theinterior of the basement. Two insulation panels 74 are retained betweenthe base plate 24 of the frame member 22 and the divider member 50 bythe retaining arms 52. As with the embodiments described above, thedivider member 50 is releasably connected to the frame member 22 forease of removing the insulation panels 74. Each insulation panel 74 ispositioned between the divider member 50 and the base plate 24 in amanner such that the acoustic membrane 20 faces the inside of the room.

In an alternate embodiment for forming a drop ceiling utilizing theremovable panel finishing system described herein, the acoustic membrane20 is mechanically affixed to the sub-floor framing members 82 in acontinuous or successive manner (not illustrated). Joints betweensuccessive acoustic membranes 20 may be sealed, such as by tape orcaulk, to form a substantially continuous acoustic membrane 20 acrossthe ceiling. A framing member 22 may be mechanically and/or adhesivelyaffixed to the sub-floor framing members 82 such that the arms 26 of theframing member 22 face downwardly and into the interior of the basement.Suitable mechanical fasteners include any conventional mechanicalfastening devices such as staples, nails, screws, tacks and the like.Insulation panels 40 are positioned between the base plate 24 of theframe member 22 and retaining arms 52 of a divider member with thefabric facing 44 facing the internal portion of the room. As with theembodiments described above, the divider member 50 is releasablyconnected to the frame member 22 so that the insulation panels 40 can beeasily removed. It is to be appreciated that the drop ceilingembodiments are described herein are described with reference to anunfinished basement, but could equally apply to any unfinished room.

The invention of this application has been described above bothgenerically and with regard to specific embodiments. Although theinvention has been set forth in what is believed to be the preferredembodiments, a wide variety of alternatives known to those of skill inthe art can be selected within the generic disclosure. The invention isnot otherwise limited, except for the recitation of the claims set forthbelow.

1. A removable panel finishing system having improved sound absorbingqualities comprising: at least one acoustic membrane affixed to studs ofa frame of a room to be finished; framing members affixed to said studsthrough said acoustic membrane, said framing members each including abase plate and two arms positioned perpendicularly to said base plate,said framing members being affixed to said studs such that said armsface inwardly into said room; a connection member releasably connectedto each of said framing members; and insulation panels positionedbetween said base plates of said framing members and said connectionmembers, said insulation panels each including an insulation core, afabric facer, and a backing facer.
 2. The removable panel finishingsystem of claim 1, wherein said at least one acoustic membrane has athickness from about 1/16 of an inch—about ⅜ of an inch.
 3. Theremovable panel finishing system of claim 2, wherein said at least oneacoustic membrane has a density of from approximately 1 lb/ft²-3lbs/ft².
 4. The removable panel finishing system of claim 3, whereinsaid acoustic membrane is selected from the group consisting of foil, afoil-faced asphalt material, elastomeric materials, composite laminates,a polymer film, a composite material that includes an organic bondingmaterial and one or more types of reinforcement fibers, a cement board,a gypsum board, a gypsum/WUCS board, a dense WUCS mat, a film formed ofa fiberglass reinforced resin, a dense polymeric material and a filmformed of a loaded polymer or copolymer.
 5. The removable panelfinishing system of claim 1, wherein said at least one acoustic membraneis affixed to said studs by a member selected from the group consistingof nails, screws, staples, tacks and adhesives.
 6. The removable panelfinishing system of claim 1, wherein joints between successive acousticmembranes are sealed by a member selected from the group consisting oftape and caulk.
 7. The removable panel finishing system of claim 1,wherein said insulation core is selected from the group consisting of afoam insulation board, a fibrous insulation board and a combination ofan insulation batt and an insulation board.
 8. The removable panelfinishing system of claim 7, wherein said fabric facer is formed of anatural or artificial fiber fabric and has an aesthetically pleasingsurface.
 9. The removable panel finishing system of claim 1, whereinsaid connection member is selected from the group consisting of a cornerframe member and a divider member.
 10. A removable panel finishingsystem having improved sound absorbing qualities comprising: framingmembers affixed to studs of a frame of a room to be finished, saidframing members each including a base plate and two arms positionedperpendicularly to said base plate, said framing members being affixedto said studs such that said arms face inwardly into said room; aconnection member releasably connected to each of said framing members;and insulation panels positioned between said base plates of saidframing members and said connection members, said insulation panels eachincluding an insulation core, an acoustic membrane, and a backing facer.11. The removable panel finishing system of claim 10, wherein saidinsulation panels are positioned such that said acoustic membrane facesinwardly into said room.
 12. The removable panel finishing system ofclaim 10, wherein said insulation panels each further include a fabricfacer and said insulation panel is positioned such that said fabricfacer faces inwardly into said room.
 13. The removable panel finishingsystem of claim 12, wherein said fabric facer is formed of a natural orartificial fiber fabric and has an aesthetically pleasing surface. 14.The removable panel finishing system of claim 10, wherein said acousticmembrane has a thickness from about ⅛ of an inch to about ¼ of an inch.15. The removable panel finishing system of claim 14, wherein saidacoustic membrane has a density of from approximately 1 lb/ft²-3lbs/ft².
 16. The removable panel finishing system of claim 15, whereinsaid acoustic membrane is selected from the group consisting of foil, afoil-faced asphalt material, elastomeric materials, composite laminates,a polymer film, a composite material including an organic bondingmaterial and one or more types of reinforcement fibers, a cement board,a gypsum board, a gypsum/WUCS board, a dense WUCS mat, a film formed ofa fiberglass reinforced resin, a dense polymeric material and a filmformed of a loaded polymer or copolymer.
 17. The removable panelfinishing system of claim 10, wherein said insulation core is selectedfrom the group consisting of a foam insulation board, a fibrousinsulation board and a combination of an insulation batt and aninsulation board.
 18. The removable panel finishing system of claim 1,wherein said connection member is selected from the group consisting ofa corner frame member and a divider member.
 19. The removable panelfinishing system of claim 10, wherein said acoustic membrane is affixedto said insulation core via an adhesive.
 20. A drop ceiling havingimproved sound absorbing qualities comprising: at least one acousticmembrane affixed to sub-floor framing members in a room to be finished;framing members affixed to said sub-floor framing members through saidat least one acoustic membrane, said framing members each including abase plate and two arms positioned perpendicularly to said base plate,said framing members being affixed to said sub-floor framing memberssuch that said arms face downwardly into said room; a connection memberreleasably connected to each of said framing members; and insulationpanels positioned between said base plates of said framing members andsaid connection members, said insulation panels each including aninsulation core, a fabric facer, and a backing facer.
 21. The dropceiling of claim 20, wherein said at least one acoustic membrane has athickness from about 1/16 of an inch—about ⅜ of an inch.
 22. The dropceiling of claim 21, wherein said at least one acoustic membrane has adensity of from approximately 1 lb/ft²-3 lbs/ft².
 23. The drop ceilingof claim 22, wherein said at least one acoustic membrane is selectedfrom the group consisting of foil, a foil-faced asphalt material,elastomeric materials, composite laminates, a polymer film, a compositematerial including an organic bonding material and one or more types ofreinforcement fibers, a cement board, a gypsum board, a gypsum/WUCSboard, a dense WUCS mat, a film formed of a fiberglass reinforced resin,a dense polymeric material and a film formed of a loaded polymer orcopolymer.
 24. The drop ceiling of claim 20, wherein said at least oneacoustic membrane is affixed to said sub-floor framing members by amember selected from the group consisting of nails, screws, staples,tacks and adhesives.
 25. The drop ceiling of claim 20, wherein jointsbetween successive acoustic membranes are sealed by a member selectedfrom the group consisting of tape and caulk.
 26. The drop ceiling ofclaim 20, wherein said insulation core is selected from the groupconsisting of a foam insulation board, a fibrous insulation board and acombination of an insulation batt and an insulation board.
 27. The dropceiling of claim 26, wherein said fabric facer is formed of a natural orartificial fiber fabric and has an aesthetically pleasing surface. 28.The drop ceiling of claim 20, wherein said connection member is selectedfrom the group consisting of a corner frame member and a divider member.29. The drop ceiling of claim 28, wherein said connection member isformed of a material selected from the group consisting of plastic andmetal.